Troubleshooting Stihl 024
The various faults that can affect a Stihl 024 chainsaw are divided into seven groups. In each group the likely symptoms are given on the left and possible causes are listed on the right. The most likely faults are given first, and so on.
Chainsaws are pretty basic engines, requiring three basic areas, along with their basic associated components in order to start and run smoothly as well as to deliver the power, efficiency and reliability that is required:
Fuel – Carburettor, Fuel filter, Fuel mix, Hoses, Primer bulb, Breather
Spark – Spark Plug, Ignition unit, HT & short Lead, Stop Switch, Flywheel
Air – Air filter, Carburettor, Manifold, Muffler, Hoses, Breather
Table of Contents
10 Basic Checks For The Stihl 024 Chainsaw
- Pull the starter rope to see if the engine turns over and if compression is adequate.
- Check fuel for quality and correct mix – recommend replacing with a known mix.
- Check the fuel filter for blockage.
- Check fuel supply pickup and hose for blockage or cracking from age.
- Check the air filter for blockage.
- Check the carburettor settings are correct (including the idle adjustment).
- Check for spark.
- Check spark plug electrode for wear or carbon build up and correct gap.
- Check the muffler spark arrestor screen, if fitted visually check hoses, manifold and cylinder base gasket for leaks.
- Remove the exhaust to check for piston seizure or ring damage if compression seems inadequate.
Stihl 024 Clutch
| Condition | Cause | Remedy |
|---|---|---|
| Saw chain stops under load at full throttle (1) | Clutch shoes badly worn | Install new clutch |
| Saw chain stops under load at full throttle (2) | Clutch drum badly worn | Install new clutch drum |
| Saw chain rotates at idle speed (1) | Engine idle speed too high | Readjust with idle speed screw LA (counterclockwise) |
| Saw chain rotates at idle speed (2) | Clutch springs stretched or fatigued | Replace the clutch springs or install new clutch |
| Saw chain rotates at idle speed (3) | Clutch spring hooks broken | Replace the clutch springs |
| Loud noises (1) | Clutch springs stretched or fatigued | Replace all clutch springs |
| Loud noises (2) | Needle cage damaged | Fit new needle cage |
| Loud noises (3) | Clutch shoe retainer broken | Fit new retainer |
| Loud noises (4) | Clutch shoes and carrier worn | Install new clutch |
Stihl 024 Chain Drive, Chain Brake, Chain Tensioner
| Condition | Cause | Remedy |
|---|---|---|
| Chain sprocket wears rapidly (1) | Chain not properly tensioned | Tension chain as specified |
| Chain sprocket wears rapidly (2) | Wrong chain pitch | Fit chain of correct pitch |
| Chain sprocket wears rapidly (3) | Insufficient chain lubrication | Check chain lubrication |
| Chain sprocket wears rapidly (4) | Chain sprocket worn | Fit new chain sprocket |
| Saw chain stops under load at full throttle (1) | Clutch shoes badly worn | Install new clutch |
| Saw chain stops under load at full throttle (2) | Clutch drum badly worn | Install new clutch drum |
| Saw chain stops under load at full throttle (3) | Brake band blocked | Check freedom of movement and operation of brake band |
| Saw chain rotates at idle speed (1) | Engine idle speed too high | Readjust with idle speed screw LA (counterclockwise) |
| Saw chain rotates at idle speed (2) | Clutch springs stretched or fatigued | Replace the clutch springs or install new clutch |
| Saw chain rotates at idle speed (3) | Clutch spring hooks broken | Replace the clutch springs |
| Saw chain does not stop activated (1) | Brake spring stretched or broken | Fit new brake spring |
| Saw chain does not stop activated (2) | Brake band stretched or worn | Fit new brake band |
| Saw chain does not stop activated (3) | Clutch drum worn | Fit new clutch drum |
Stihl 024 Chain Lubrication
In the event of trouble with the chain lubrication system, check and rectify other sources of faults before disassembling the oil pump.
| Condition | Cause | Remedy |
|---|---|---|
| Chain receives no oil (1) | Oil tank empty | Fill up with oil and check setting of oil pump if necessary |
| Chain receives no oil (2) | Oil inlet hole in guide bar is blocked | Clean oil inlet hole |
| Chain receives no oil (3) | Intake hose or pickup body clogged or intake hose ruptured | Fit new intake hose and pickup body |
| Chain receives no oil (4) | Valve in oil tank blocked | Clean or replace valve |
| Chain receives no oil (5) | Teeth on worm worn | Install new worm |
| Chain receives no oil (6) | Oil pump damaged or worn | Install new oil pump |
| Machine losing chain oil (1) | Oil pump body damaged | Install new oil pump |
| Machine losing chain oil (2) | Oil pump damaged or worn | Install new oil pump |
| Machine losing chain oil (3) | Oil suction hose connection damaged | Install new oil intake hose |
| Oil pump delivers insufficient oil (4) | Oil pump worn | Install new oil pump |
| Oil pump delivers insufficient oil (5) | Oil pump delivery rate set too low | Adjust oil pump (only on version with adjustable oil pump) |
Stihl 024 Rewind Starter
| Condition | Cause | Remedy |
|---|---|---|
| Starter rope broken (3) | Rope pulled out too vigorously as far as stop or over edge, i.e. not vertically | Fit new starter rope |
| Starter rope broken (2) | Normal wear | Fit new starter rope |
| Starter rope does not rewind (3) | Very dirty or corroded | Clean or replace rewind spring |
| Starter rope does not rewind (4) | Insufficient spring tension | Check rewind spring and increase tension |
| Starter rope does not rewind (5) | Rewind spring broken | Fit new rewind spring |
| Starter rope cannot be pulled out far enough | Spring over tensioned | Check rewind spring and reduce tension |
| Starter rope can be pulled out almost without resistance (crankshaft does not turn) (1) | Guide peg on pawl or pawl itself is worn | Fit new pawl |
| Starter rope can be pulled out almost without resistance (crankshaft does not turn) (2) | Spring clip on pawl fatigued | Fit new spring clip |
| Starter rope is difficult to pull or rewinds very slowly (1) | Starter mechanism is very dirty | Thoroughly clean complete starter mechanism |
| Starter rope is difficult to pull or rewinds very slowly (2) | Lubricating oil on rewind spring becomes viscous at very low outside temperatures (spring windings stick together) | Coat rewind spring with a little standard solvent-based degreasant (containing no chlorinated or halogenated hydrocarbons), then pull rope carefully several times until normal action is restored |
| Starter rope is difficult to pull or rewinds very slowly (3) | Decompression valve is not open | Open, check and replace decompression valve if necessary |
Stihl 024 Ignition System
Exercise extreme caution while carrying out maintenance and repair work on the ignition system. The high voltages which occur can cause serious or fatal accidents.
| Condition | Cause | Remedy |
|---|---|---|
| Engine runs roughly, misfires, temporary loss of power (1) | Spark plug boot is loose | Press boot firmly onto spark plug and fit new spring if necessary |
| Engine runs roughly, misfires, temporary loss of power (2) | Spark plug sooted, smeared with oil | Clean the spark plug or replace if necessary. If sooting keeps recurring, check air filter |
| Engine runs roughly, misfires, temporary loss of power (3) | Ignition lead loose in ignition module | Secure ignition lead properly |
| Engine runs roughly, misfires, temporary loss of power (4) | Fuel/oil mixture – too much oil | Use correct mixture of fuel and oil |
| Engine runs roughly, misfires, temporary loss of power (5) | Incorrect air gap between ignition module and flywheel | Set air gap correctly |
| Engine runs roughly, misfires, temporary loss of power (6) | Flywheel cracked or has other damage or pole shoes have turned blue | Install new flywheel |
| Engine runs roughly, misfires, temporary loss of power (7) | Ignition timing wrong, flywheel out of adjustment, key in flywheel has sheared off | Fit key if necessary and secure flywheel properly or install new flywheel |
| Engine runs roughly, misfires, temporary loss of power (8) | Weak magnetization in flywheel | Install new flywheel |
| Engine runs roughly, misfires, temporary loss of power (9) | Irregular spark | Check operation of switch shaft/contact springs and ignition module. Faulty insulation or break in ignition lead or short circuit wire. Check ignition lead/ignition module and replace ignition module if necessary. Check operation of spark plug. Clean the spark plug or replace if necessary. |
| Engine runs roughly, misfires, temporary loss of power (10) | Crankcase damaged (cracks) | Install new crankcase |
| No spark (1) | Spark plug faulty | Install new spark plug |
| No spark (2) | Faulty insulation or short in short circuit wire | Check short circuit wire for short circuit to ground |
| No spark (3) | Break in ignition lead or insulation damaged | Check ignition lead and replace if necessary |
| No spark (4) | Ignition module faulty | Install new ignition module |
Stihl 024 Carburetor
| Condition | Cause | Remedy |
|---|---|---|
| Carburetor floods; engine stalls (1) | Inlet needle not sealing – foreign matter in valve seat or cone | Remove and clean the inlet needle, clean the carburetor |
| Carburetor floods; engine stalls (2) | Inlet control lever sticking on spindle | Check inlet control lever, replace if necessary |
| Carburetor floods; engine stalls (3) | Helical spring not located on nipple of inlet control lever | Remove the inlet control lever and refit it correctly |
| Carburetor floods; engine stalls (4) | Perforated disc on diaphragm is deformed and presses constantly against the inlet control lever | Fit a new metering diaphragm |
| Carburetor floods; engine stalls (5) | Metered diaphragm deformed | Fit a new metering diaphragm |
| Poor acceleration (1) | Setting of low speed screw too lean | Check basic carburetor setting, correct if necessary |
| Poor acceleration (2) | Setting of high speed screw too lean | Check basic carburetor setting, correct if necessary |
| Poor acceleration (3) | Inlet needle sticking to valve seat | Remove inlet needle, clean and refit |
| Poor acceleration (4) | Diaphragm gasket leaking | Fit new diaphragm gasket |
| Poor acceleration (5) | Metering diaphragm damaged or shrunk | Fit a new metering diaphragm |
| Poor acceleration (6) | Impulse hose damaged or kinked | Install new impulse hose |
| Poor acceleration (7) | Tank vent faulty | Replace tank vent |
| Poor acceleration (8) | Leak on fuel hose from tank to carburetor | Seal connections or install new fuel hose |
| Engine will not idle, idle speed too high (3) | Throttle shutter opened too wide by idle speed screw LA | Reset idle speed screw LA correctly |
| Engine will not idle, idle speed too high (3) | Oil seals/crankcase leaking | Seal or replace oil seals/crankcase |
| Engine stalls at idle speed (1) | Idle jet bores or ports blocked | Clean the carburetor |
| Engine stalls at idle speed (2) | Setting of low speed screw too rich or too lean | Reset low speed screw L correctly |
| Engine stalls at idle speed (3) | Setting of idle speed screw LA incorrect – throttle shutter completely closed | Reset idle speed screw LA correctly |
| Engine stalls at idle speed (4) | Tank vent faulty | Replace tank vent |
| Engine stalls at idle speed (5) | Leak on fuel hose from tank to carburetor | Seal connections or install new fuel hose |
| Engine speed drops quickly under load – low power (1) | Air filter dirty | Clean air filter or replace if necessary |
| Engine speed drops quickly under load – low power (2) | Throttle shutter not opened fully | Check throttle cable and rod |
| Engine speed drops quickly under load – low power (3) | Tank vent faulty | Replace tank vent |
| Engine speed drops quickly under load – low power (4) | Fuel pickup body dirty | Install new pickup body |
| Engine speed drops quickly under load – low power (5) | Fuel strainer dirty | Clean fuel strainer in carburetor, replace if necessary |
| Engine speed drops quickly under load – low power (6) | Leak on fuel hose from tank to carburetor | Seal connections or install new fuel hose |
| Engine speed drops quickly under load – low power (7) | Setting of high speed screw H too rich | Check basic carburetor setting, correct if necessary |
| Engine speed drops quickly under load – low power (8) | Main jet bores or ports blocked | Clean the carburetor |
| Engine speed drops quickly under load – low power (9) | Pump diaphragm damaged or fatigued | Fit new pump diaphragm |
| Engine speed drops quickly under load – low power (10) | Impulse hose damaged or kinked | Install new impulse hose |
| Engine speed drops quickly under load – low power (11) | Ignition timing wrong, flywheel out of adjustment, key in flywheel is missing or has sheared off | Fit key if necessary and secure flywheel properly or install new flywheel |
Stihl 024 Engine
Always check and, if necessary, repair the following parts before looking for faults on the engine:
- Air filter
- Fuel system
- Carburetor
- Ignition system
| Condition | Cause | Remedy |
|---|---|---|
| Engine does not start easily, stalls at idle speed, but operates normally at full throttle (1) | Oil seals in crankcase damaged | Replace the oil seals |
| Engine does not start easily, stalls at idle speed, but operates normally at full throttle (2) | Crankcase leaking or damaged (cracks) | Seal or replace the crankcase |
| Engine does not deliver full power or runs erratically (1) | Piston rings worn or broken | Fit new piston rings |
| Engine does not deliver full power or runs erratically (2) | Muffler / spark arresting screen carbonized | Clean the muffler (inlet and exhaust), replace spark arresting screen, replace muffler if necessary |
| Engine does not deliver full power or runs erratically (3) | Air filter dirty | Replace air filter |
| Engine does not deliver full power or runs erratically (4) | Fuel/impulse hose severely kinked or damaged | Fit new hoses or position them free from kinks |
| Engine does not deliver full power or runs erratically (5) | Decompression valve is not closed | Close, check and replace decompression valve if necessary |
| Engine overheating | Insufficient cylinder cooling. Air inlets in fan housing blocked or cooling fins on cylinder very dirty | Thoroughly clean all cooling air openings and the cylinder fins |
Troubleshooting methods
In addition to the faults described in the above tables, trouble shooting can be carried out on specific components or sub-systems of the chainsaw. The various procedures are described in the relevant chapters (see the full manual on this website), see the contents page, as follows:
- Checking the operation of the chain brake
- Measuring the resistance of the stop plate
- Pressure testing the carburettor
- Pressure testing the decompression valve
- Pressure testing the cylinder
Stihl 024 Chainsaw workshop Manual and parts list available